Charge coolers have finally arrived

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After a long wait I can finally get on with fabricating the induction side, even though I measured the available space they are huge. Picture is of one cooler resting somewhere near its final position, opposite side of engine is stripped down ready for fuel pumps positioning (they should be in the UK today so hoping for speedy customs processing) so will be a busy few months ahead. Next job will be ECU and making the loom, I am going to go Megasquirt MS3 PRO route, is anyone else running Megasquirt ?
Regards Tim

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Everything is being mocked up and will be removed for engine mods. When engine is refitted lots of heat protection will be added

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Are you running forced induction?,The intakes on mine are 3.5'' and the matrix inside look similar to a bar and plate design but with larger air and smaller water passages 6.5'' square body and 1'' water in and out and 15'' overall length, and quite heavy so designed for some serious boost, miles over specified for what's needed but I shouldn't have a problem cooling the air.

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charge coolers are from Silicone intakes I would say that they are the same coolers as Frozen Boost Type 26. Probably made in China, came in the same non de-script brown cardboard boxes that you see every where these days. Bar and plate design not tubes for the core. Manifold uses twin scroll turbo (two inlets) and I have tried to keep cylinder to cylinder pulses separate (supposed to help turbo spool up quicker) so design is different bank to bank. Picture is of drivers side , 1 + 2 linked together and 3 + 4. on other side it is 1 + 3 and 2 + 4 (not firing order just counting back from front of engine). second is of breather system I have just made for gearbox and engine

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weird no second image now.

intakes for the turbos will probably be side body intakes above each fuel tank, passangers side is empty as not using air oil cooler, fitted laminova oil cooler pre heater. Drivers side will need A/C rad tilting to get cool air, or may use roof intake for both sides I will have to see which route is the best once the charge coolers are fitted and plumbed to the intake manifold and recirculation valves fitted

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Have you any more info on the water injection system or pictures, I have some room left beside the gearbox where I could fabricate a tank and another pump shouldn't be a problem. I have been looking at Snow and AEM systems, what size nozzles did you use for the LS engines?
Regards Tim

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Engine is 5.3 iron block (may put 4.8 crank in it) will be running all steel bottom end forged pistons, trick flow 215s, roller rockers, haven't finalised cam spec yet, ARP stud kit,electric water pump, dry sump,laminova oil coolers pre heaters for engine and gearbox, maybe water injection
once I have fitted all the ancillary's (fuel+gearbox pumps,roller rockers etc have cleared customs) engine will be coming out for machining and I will build and run engine to make sure everything works before the body goes on
Megasquirt MS3 PRO will look after everything that I need and more, just got to get my old farts brain around to programming the thing

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From the limited research that I have done on the Megasquirt there does seem to be a lot of online support from people who have built the system in component form and designed features that they need and make available to others. There is an expert in the Midlands who has been involved from the start, again I haven't researched him but I have heard his name mentioned on you tube Megasquirt tutorials. I have bought the book Performance Fuel Injection Systems written by a couple of guys who work for DIY Auto tune a Megasquirt dealer that gives a good overview of fuel injection systems not just Megasquirt and that you can do it . Will have to let you know how that goes but the price is right. My initial interest was for the fully sequential fuel and ignition for the emissions on idle (cam choice dependent)which I thought will give me more chance of passing

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Iron block for strength and cost ($299 + tax and shipping brand new), if I was worried about weight I could loose the extra with a diet

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Deal is through Summit, they are also offering a new 5.3l bored and honed to 5.7l

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Check out the Truckin magazine vortec 5,3l big bang site you may see a few similarities with my build apart from the all steel bottom end. I prefer to build in some reliability rather than wait for a failure. The potential of these engines is amazing, its only the packaging within the body constraints of the Ultima that takes some working out with turbos, it should give me a docile drivable car at low to mid rpm and a monster the more you press the peddle (ecu can electronically control different in gear boost levels to avoid to much wheel spin until the car can hook up) and for way less money than a highly tuned LS7

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Made the breather pot and oil catch tank, plumbed in the gearbox laminova pre heater/cooler,filter, one way valve and pump.Engine floor panel made (see other post)just needs cleaning up and painting,and now starting on the fuel system. Have had a job getting all the filters and pumps in but have sorted that out now, once I finish that I will be moving on to the inlet manifold which need another set of injector bungs welding in and then I can mount the charge coolers and sort the air pipes and recirculation valves, still lots to make and it doesn't look like much progress when you stand back and take a look. Pulled of the fuel tanks to get a bit more access and you can see the laminova engine oil cooler well now, but not the dry sump pump, alternator and ignition coils
Regards Tim

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Fuel pumps and filters are finally in with mm to spare

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installed

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installed

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Enough clearance for engine movement under acceleration between AC Compressor and pump, this is the second attempt as the first wouldn't fit in the space

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update on work to date, injector bungs made and tig welded on to manifold (need to order the extra injectors) one charge cooler mount welded and fitted and am now constructing the 3.5'' intake tubing from charge coolers to intake manifold. Really pleased with the way the aluminium welding has gone this time

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missing a few pictures

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good day in the garage today, both charge cooler mounts, turbo to charge cooler bends and one charge cooler to inlet manifold tube. Ancillary s are filling all the space,re circulation valves, turbo air inlet and filter housings left to fabricate and one job is complete then finish off fuel system and on to the part i'm not looking forward to, making the engine loom for the Megasquirt MS3 Pro.